reactor

Abstract

To provide a reactor capable of suppressing leakage of resin from a mold when manufacturing a core by molding.SOLUTION: A reactor 100 includes a coil 10, a core 20 containing a resin mixed with a magnetic material as a main component and covering at least a portion of the coil 10, and a case 30 that houses the coil 10 and the core 20. Of lead portions 13a and 13b which are portions where a conductor wire 1 of the coil 10 is led out to the outside of the coil 10, a lead portion from which the outermost conductor wire 1 is led out is bent inward and then is pulled outward.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a reactor. [Background technology]

[0002] A reactor is a passive element that uses inductance, and in recent years has been installed in various electronic devices as a circuit element. For example, inverters installed in vehicles such as electric vehicles, hybrid vehicles, and fuel cell vehicles incorporate converters that step up or step down battery voltage, and reactors are used as key components of these converters.

[0003] As one such reactor, Patent Document 1 discloses a reactor having a structure in which a core with a coil embedded therein is housed in an outer case. Patent Document 1 discloses that an edgewise wound alpha winding coil or a flatwise wound alpha winding coil can be used as the coil, and that the coil conductor is configured to be drawn out to one short side of the rectangular coil.

[0004] Patent Document 1 also describes a method for manufacturing a reactor by placing a coil inside an outer case, filling it with a mixed powder containing soft magnetic powder, and then pouring in a resin to impregnate and harden it to form a core.

[0005] One possible method is to manufacture the core by molding using a metal mold without using an outer case. That is, the coil is placed in a metal mold, and magnetic powder resin, which is obtained by premixing mixed powder and resin, is filled into the metal mold and cured to manufacture the core.

[0006] 22 is a diagram schematically illustrating a state in which coil 200 is placed in a mold 210 in order to produce a core of the reactor described in Patent Document 1 by molding. The core can be produced by filling mold 210 with coil 200 and then hardening it after magnetic powder resin has been filled in. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 6795979 Summary of the Invention [Problem to be solved by the invention]

[0008] Here, in the coil 200 of the reactor described in Patent Document 1, the outermost conductor 201 is pulled out linearly from the wound portion to the outside. Therefore, when the magnetic powder resin is filled into the mold 210, there is a possibility that the magnetic powder resin will leak out from the gap 220 between the mold 210 and the pulled-out portion of the conductor 201.

[0009] The present invention is intended to solve the above-mentioned problems, and has an object to provide a reactor that can prevent resin from leaking out of a mold when a core is produced by molding. [Means for solving the problem]

[0010] The reactor of the present invention comprises: A coil and a core containing a resin mixed with a magnetic material as a main component and covering at least a portion of the coil; a case that houses the coil and the core; Equipped with Of the lead-out portions, which are the portions where the conductor wire of the coil is led out to the outside of the coil, the lead-out portion where the outermost conductor wire is led out is characterized in that it is bent toward the inner periphery and then led out to the outside. [Effects of the Invention]

[0011] According to the reactor of the present invention, the pull-out portion from which the outermost conductor is pulled out is bent toward the inner periphery of the coil and then pulled out to the outside, so that when a core containing, as its main component, a resin mixed with a magnetic material is formed by molding using a mold, leakage of resin from the mold can be prevented. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic perspective view of a reactor according to an embodiment of the present invention. [Figure 2] 2 is a schematic cross-sectional view taken along line II-II of the reactor shown in FIG. 1. [Figure 3] 3 is a schematic cross-sectional view taken along line III-III of the reactor shown in FIG. 1. [Figure 4] 4 is a schematic cross-sectional view taken along line IV-IV of the reactor shown in FIG. 1. [Figure 5] FIG. 2 is a schematic perspective view of a coil. [Figure 6] 5. (a) is a schematic top view of the coil shown in FIG. 5 as viewed from the direction of arrow Y1, and (b) is a schematic side view of the coil shown in FIG. 5 as viewed from the direction of arrow Y2. [Figure 7] FIG. 10 is a perspective view schematically showing how an insulating spacer is inserted between the first and second layers of the coil. [Figure 8] FIG. 2 is a perspective view schematically showing a coil of the reactor covered with insulating resin. [Figure 9] 8(a) is a schematic side view of the coil shown in FIG. 8 when viewed from the direction of arrow Y3, and FIG. 8(b) is a schematic front view of the coil shown in FIG. 8 when viewed from the direction of arrow Y4. [Figure 10] (a) is a schematic bottom view of the first main surface side of the core when viewed in the direction of the winding axis of the coil, and (b) is a schematic top view of the second main surface side of the core. [Figure 11] 1(a) is a schematic front view of the core as viewed from the drawing direction, and FIG. 1(b) is a schematic side view of the core as viewed from a direction perpendicular to the drawing direction. [Figure 12] FIG. 2 is a perspective view schematically illustrating only a coil and a core covered with an insulating resin in a reactor. [Figure 13] 5(a) to 5(d) are diagrams illustrating a method for manufacturing a reactor according to one embodiment. [Figure 14] 14(a) to 14(d) are diagrams illustrating the method for manufacturing the reactor following FIG. 13. [Figure 15] FIG. 10 is a perspective view schematically showing a state in which a coil is arranged in a first lower mold. [Figure 16] 10 is an enlarged view of the periphery of the first lead-out portion and the second lead-out portion of the coil when placed in the first lower mold. FIG. [Figure 17] (a) is a diagram showing a schematic diagram of a coil in this embodiment being sandwiched between a first lower mold and a first upper mold, and (b) is a diagram showing a schematic diagram of a coil in which the first draw-out portion is not raised to the same height as the second draw-out portion being sandwiched between a first lower mold and a first upper mold. [Figure 18] FIG. 10 is a perspective view schematically showing a state in which a coil covered with insulating resin is placed in a second lower mold. [Figure 19] (a) is an enlarged view of the area around the first and second lead-out portions of a coil of the present invention placed on a second lower mold, and (b) is an enlarged view of the area around the first and second lead-out portions of a coil placed on a second lower mold, in which the first and second lead-out portions are not bent toward the inner circumference but are instead drawn outward. [Figure 20] (a) is a front view showing a schematic configuration of the second lower mold and second upper mold sandwiching the coil of the present invention when viewed from the drawing direction, and (b) is a front view showing a schematic configuration of the second lower mold and second upper mold sandwiching the coil in which the first draw-out portion and the second draw-out portion are not bent toward the inner periphery but are drawn outward as they are when viewed from the drawing direction. [Figure 21]18, (a) is a diagram showing a schematic view of the shape of a core formed using the second lower mold shown in FIG. 18 when viewed from the drawing direction, and (b) is a diagram showing a schematic view of the shape of a core formed using the second lower mold in which the height of the end of the coil in the short direction is approximately the same height as the upper end of the coil covered with insulating resin when viewed from the drawing direction. [Figure 22] FIG. 10 is a diagram schematically showing a state in which a coil is placed in a mold for producing a core of the reactor described in Patent Document 1 by molding. DETAILED DESCRIPTION OF THE INVENTION

[0013] The features of the present invention will be specifically described below by showing embodiments of the present invention.

[0014] Fig. 1 is a schematic perspective view of a reactor 100 according to one embodiment of the present invention. Fig. 2 is a schematic cross-sectional view of the reactor 100 shown in Fig. 1 taken along line II-II. Fig. 3 is a schematic cross-sectional view of the reactor 100 shown in Fig. 1 taken along line III-III. Fig. 4 is a schematic cross-sectional view of the reactor 100 shown in Fig. 1 taken along line IV-IV.

[0015] The reactor 100 in one embodiment includes a coil 10, a core 20, and a case 30.

[0016] Fig. 5 is a schematic perspective view of the coil 10. Fig. 6(a) is a schematic top view of the coil 10 shown in Fig. 5 when viewed from the direction of arrow Y1, and Fig. 6(b) is a schematic side view of the coil 10 shown in Fig. 5 when viewed from the direction of arrow Y2. Note that a fixing member 14, which will be described later, is omitted from Fig. 6.

[0017] In this embodiment, the conductor 1 of the coil 10 is wound in a rectangular shape. As shown in Figure 6(a), when the coil 10 is viewed in the direction in which the winding axis extends (hereinafter referred to as the winding axis direction), the corners of the conductor 1 wound in a rectangular shape are rounded, but they do not have to be rounded.

[0018] The conductor 1 is made of a metal material such as copper (C1020 or C1110), aluminum, or an alloy thereof, and its surface is coated with an enamel material such as polyimide or polyamideimide. The cross-sectional shape of the conductor 1 is, for example, rectangular or circular. However, the present invention is not limited by the material or cross-sectional shape of the conductor 1. In this embodiment, the conductor 1 is a rectangular wire with a rectangular cross-sectional shape. As an example, the width of the conductor 1 is 16 mm, the thickness is 1.4 mm, and the thickness of the enamel material coating the conductor 1 is 40 μm.

[0019] In this embodiment, the conductor wire 1 of the coil 10 is wound flatwise and alpha winding. As shown in Fig. 5, the coil 10 includes a first layer 11 in which the conductor wire 1 is wound from the outer periphery to the inner periphery, and a second layer 12 in which the conductor wire 1 is wound up to the innermost periphery of the first layer 11 and then continues to be wound from the inner periphery to the outer periphery. Here, of the lead-out portions of the conductor wire 1 of the coil 10 that are drawn out to the outside of the coil 10, the portion drawn out from the outermost periphery of the first layer 11 to the outside is referred to as first lead-out portion 13a, and the portion drawn out from the outermost periphery of the second layer 12 to the outside is referred to as second lead-out portion 13b.

[0020] The flatwise wound coil 10 is formed by bending the short side (thickness direction) of the cross section of the rectangular conductor 1 and winding it into a spiral shape. When the winding axis is oriented vertically, the flatwise wound coil 10 has low thermal conductivity in the horizontal direction of the reactor 100 but good thermal conductivity in the vertical direction.

[0021] In the coil 10 of this embodiment, the first lead portion 13a and the second lead portion 13b are located at the same height in the direction of the winding axis of the coil 10. That is, the first lead portion 13a, which is led out from the outermost periphery of the first layer 11 to the outside of the coil 10, is configured to be raised to the height of the second layer 12 and then led out, as shown in Figures 5 and 6(b). Note that "located at the same height" means that the first lead portion 13a and the second lead portion 13b are both located at the height of the second layer 12 of the coil 10, and it is not necessary for the heights of the two to be exactly the same.

[0022] 5 and 6, in this embodiment, the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 are each led out to the short side of the coil 10 around which the conducting wire 1 is wound in a rectangular shape. However, the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 may each be led out to the long side of the coil 10.

[0023] Of the first lead-out portion 13a and the second lead-out portion 13b of the coil 10, the lead-out portion of the conductor 1 at the outermost periphery is bent inward and then led outward. In this embodiment, the conductor 1 of the coil 10 is wound using flatwise winding and alpha winding, so the first lead-out portion 13a and the second lead-out portion 13b are each the lead-out portion of the conductor 1 at the outermost periphery. Therefore, as shown in FIGS. 5 and 6(a), both the first lead-out portion 13a and the second lead-out portion 13b are bent inward and then led outward. For ease of understanding, in FIG. 6(a), the lead-out portion when the conductor 1 is not bent inward and is simply led outward from the coil 10 is shown by a dotted line.

[0024] 6(a), the distance S1 between the first lead-out portion 13a and the second lead-out portion 13b in the direction perpendicular to the direction in which the conductor wire 1 is drawn out is smaller than the dimension S2 of the coil 10. However, the distance S1 between the first lead-out portion 13a and the second lead-out portion 13b is the distance from the outside of the first lead-out portion 13a to the outside of the second lead-out portion 13b, and the dimension S2 of the coil 10 is the dimension between the two outsides of the coil 10 in the direction perpendicular to the direction in which the conductor wire 1 is drawn out.

[0025] Coil 10 has first and second main surfaces 10a and 10b that face each other in the direction of the winding axis. Coil 10 is arranged so that the direction of the winding axis coincides with the direction in which bottom surface 30a and lid 30f of case 30, which will be described later, face each other. In this embodiment, first main surface 10a of coil 10 is located on the bottom surface 30a side of case 30, and second main surface 10b is located on the lid 30f side of case 30.

[0026] In this embodiment, the coil 10 is fixed by fixing members 14, as shown in FIG. 5. The fixing members 14 may be any material capable of fixing the wound conductive wire 1, and may be, for example, heat-resistant Kapton (registered trademark) tape made of polyimide resin. Fixing the coil 10 by the fixing members 14 prevents the coil 10 from expanding, thereby preventing deterioration in the characteristics of the coil 10. In the example shown in FIG. 5, the coil 10 is fixed at six locations by six fixing members 14, but there are no particular restrictions on the positions or number of fixing members 14 at which the coil 10 is fixed. It is also possible to configure the coil 10 without providing the fixing members 14.

[0027] In this embodiment, an insulating spacer 15 is disposed between the first layer 11 and the second layer 12 of the coil 10 (see FIG. 7). That is, when manufacturing the coil 10, the conductive wire 1 is wound flatwise and alpha-wound, and then the insulating spacer 15 is inserted between the first layer 11 and the second layer 12 as shown in FIG. 7. Thereafter, the coil 10 is fixed with a fixing member 14.

[0028] The insulating spacer 15 is made of, for example, fluororesin and has a thickness of, for example, 1 mm. In the example shown in FIG. 7, the insulating spacer 15 has a U-shape, but the shape of the insulating spacer 15 is not limited to a U-shape. By disposing the insulating spacer 15 between the first layer 11 and the second layer 12 of the coil 10, it is possible to more reliably insulate the conductor 1 of the first layer 11 from the conductor 1 of the second layer 12, which have a voltage difference. However, if the insulation between the conductor 1 of the first layer 11 and the conductor 1 of the second layer 12 is guaranteed, the insulating spacer 15 can be omitted.

[0029] In this embodiment, at least a portion of the coil 10 is covered with a non-magnetic insulating resin 40. By configuring the coil 10 to be covered with the insulating resin 40, the insulation properties of the coil 10 can be improved, and the heat dissipation properties of the coil 10 via the insulating resin 40 can also be improved.

[0030] Fig. 8 is a perspective view schematically showing the coil 10 of the reactor 100 covered with insulating resin 40. Fig. 9(a) is a schematic side view of the coil 10 shown in Fig. 8 when viewed from the direction of arrow Y3, and Fig. 9(b) is a schematic front view of the coil 10 shown in Fig. 8 when viewed from the direction of arrow Y4. Here, the direction of arrow Y4, i.e., the direction in which the conductor wire 1 of the first lead portion 13a and the second lead portion 13b is drawn out, is referred to as the drawing direction.

[0031] The insulating resin 40 is made of, for example, an epoxy resin containing silica as a filler. In this case, the thermal conductivity of the insulating resin 40 is, for example, 3 W / mK. However, the resin constituting the insulating resin 40 is not limited to epoxy resin, and the filler is not limited to silica. For example, if a thermal conductivity of 5 W / mK or higher is desired, alumina can be used as the filler.

[0032] As will be described later, the insulating resin 40 can be formed by molding using a mold. In this case, it is preferable to provide the mold with a draft angle to make it easier to remove the molded product from the mold. Therefore, the surface of the insulating resin 40 covering the coil 10 is inclined with respect to the vertical direction.

[0033] Specifically, as shown in FIG. 9(b), when the coil 10 covered with the insulating resin 40 is viewed from the unwinding direction, the surface of the insulating resin 40 covering the side surfaces of the coil 10 is inclined with respect to the vertical direction. In this embodiment, as shown in FIG. 9(b), when the coil 10 is viewed from the unwinding direction, the surface of the insulating resin 40 covering the side surfaces of the coil 10 has a central portion 40a located outermost in the direction of the winding axis of the coil 10. In other words, the thickness of the insulating resin 40 covering the side surfaces of the coil 10 when viewed from the unwinding direction is thickest at the central portion 40a in the direction of the winding axis of the coil 10 and thinnest at the upper and lower ends. Note that the side surfaces of the coil 10 when viewed from the unwinding direction refer to the side surfaces of the long sides of the coil 10.

[0034] 9(a), when the coil 10 covered with the insulating resin 40 is viewed from a direction perpendicular to the drawing direction, the surface of the insulating resin 40 covering the side surface of the coil 10 is inclined with respect to the vertical direction. In this embodiment, as shown in FIG. 9(a), the surface of the insulating resin 40 is positioned more outward from the lower end of the coil 10 on the first layer 11 side toward the upper end of the coil 10 on the second layer 12 side. In other words, the thickness of the insulating resin 40 covering the side surface of the coil 10 when viewed from a direction perpendicular to the drawing direction is thickest at the upper end of the coil 10 on the second layer 12 side and thinnest at the lower end of the coil 10 on the first layer 11 side. Note that the side surface of the coil 10 when viewed from a direction perpendicular to the drawing direction refers to the side surface on the short side of the coil 10.

[0035] As described above, the surface of the insulating resin 40 covering the coil 10 is inclined relative to the vertical direction, which makes it easier to remove the molded product from a mold when the insulating resin 40 is formed by molding using a mold. Therefore, the surface of the insulating resin 40 is kept clean. Furthermore, when the coil 10 covered with the insulating resin 40 is viewed from the drawing direction, the shape of the insulating resin 40 is hexagonal, and all angles (vertices) formed by adjacent sides can be obtuse angles (greater than 90°). Making all angles obtuse in this way means that the angles formed by adjacent sides in the inner shape of the core 20 (described later) are obtuse angles (following the shape of the insulating resin 40). This makes it possible to suppress the occurrence of cracks originating from each corner inside the core 20, thereby improving the reliability of the reactor 100.

[0036] The shape of the insulating resin 40 corresponds to the shape of the core 20, which will be described later.

[0037] The insulating resin 40 is provided in a manner that covers at least the curved portions of the first lead portion 13a and the second lead portion 13b of the coil 10. As described above, the first lead portion 13a and the second lead portion 13b of the coil 10 are bent toward the inner periphery and then drawn outward, as shown in FIGS. 5 and 6(a). The insulating resin 40 is provided in a manner that covers the portions of the first lead portion 13a and the second lead portion 13b of the coil 10 where the conductor 1 is bent from the outermost periphery toward the inner periphery. Therefore, as shown in FIG. 8, the portions of the first lead portion 13a and the second lead portion 13b of the coil 10 that are not covered with the insulating resin 40 extend linearly. By covering at least the curved portions of the first lead portion 13a and the second lead portion 13b of the coil 10 with the insulating resin 40, an insulation distance from the core 20 can be ensured. Furthermore, when the core 20 is formed by molding using a metal mold, the curved portion of the coil 10 covered with the insulating resin 40 can also be securely sandwiched by the metal mold.

[0038] The core 20 is provided so as to cover at least a portion of the coil 10. In this embodiment, the core 20 covers both side surfaces on the long sides of the coil 10 around which the conducting wire 1 is wound in a rectangular shape, the inside of the coil 10, and a portion of the first main surface 10a and a portion of the second main surface 10b of the coil 10.

[0039] The core 20 mainly contains a resin mixed with a magnetic material such as a soft magnetic metal or ferrite material. The main component is the component with the highest content. The soft magnetic metal material is not particularly limited, and examples include crystalline alloy powder materials such as Fe-Si alloys, Fe-Si-Cr alloys, Fe-Al alloys, Fe-Ni alloys, and Fe-Co alloys; amorphous materials with excellent soft magnetic properties that are primarily composed of Fe; and nanocrystalline metal materials with a mixture of amorphous and nanocrystalline phases. When using such soft magnetic metal materials, it is preferable to form a coating layer made of an insulating material such as phosphate or silicone resin on the surface of the metal powder to ensure insulation.

[0040] The ferrite material is also not particularly limited, and various ferrite materials containing Fe2O3 as the main component, such as Ni-based, Cu-Zn-based, Ni-Zn-based, Mn-Zn-based, and Ni-Cu-Zn-based, can be used.

[0041] The resin contained in the core 20 is, for example, an epoxy resin. However, the resin is not limited to epoxy resin, and other types of resins such as silicone resin may also be used.

[0042] The core 20 includes a first main surface portion 20a that covers the first main surface 10a of the coil 10 and a second main surface portion 20b that covers the second main surface 10b of the coil 10. Note that the embodiment in which the first main surface portion 20a of the core 20 covers the first main surface 10a of the coil 10 also includes an embodiment in which the first main surface portion 20a covers the first main surface 10a of the coil 10 that is covered with the insulating resin 40. Similarly, the embodiment in which the second main surface portion 20b of the core 20 covers the second main surface 10b of the coil 10 also includes an embodiment in which the second main surface portion 20b covers the second main surface 10b of the coil 10 that is covered with the insulating resin 40.

[0043] Figure 10(a) is a schematic bottom view of the first main surface portion 20a side of the core 20 when viewed in the direction of the winding axis of the coil 10, and Figure 10(b) is a schematic top view of the second main surface portion 20b side of the core 20.

[0044] A first recess 21a is provided on the first main surface 20a of the core 20, and a second recess 21b is provided on the second main surface 20b. That is, when the first main surface 10a of the coil 10 is completely covered, the shape of the first main surface 20a of the core 20 when viewed in the direction of the winding axis of the coil 10 is usually rectangular, but the first recess 21a is provided so as to be recessed inward relative to the rectangular shape. Similarly, when the second main surface 10b of the coil 10 is completely covered, the shape of the second main surface 20b of the core 20 when viewed in the direction of the winding axis of the coil 10 is usually rectangular, but the second recess 21b is provided so as to be recessed inward relative to the rectangular shape.

[0045] In this embodiment, as shown in Fig. 10(a), the first recesses 21a are provided at the ends of the long sides and the short sides of the first main surface portion 20a of the core 20. The ends of the long sides and the short sides of the first main surface portion 20a are based on a rectangular shape in which the first recesses 21a are not provided. More specifically, the first recesses 21a are provided at each of the ends of a pair of short sides of the first main surface portion 20a.

[0046] The first recess 21a may be provided at the end of the long side of the first main surface portion 20a, or one first recess 21a may be provided at only one of the end of the pair of short sides. However, for reasons described later, it is preferable to provide the first recess 21a at each of the end of the pair of short sides of the first main surface portion 20a.

[0047] 10(b), in this embodiment, the second recesses 21b are provided at the ends of the long sides and the ends of the short sides of the second main surface portion 20b of the core 20. The ends of the long sides and the short sides of the second main surface portion 20b are based on a rectangular shape in which the second recesses 21b are not provided. More specifically, the second recesses 21b are provided at each of the ends of a pair of short sides of the second main surface portion 20b.

[0048] The second recess 21b may be provided at the end of the long side of the second main surface portion 20b, or one second recess 21b may be provided at only one of the end of the pair of short sides. However, for reasons described later, it is preferable to provide the second recess 21b at each of the end of the pair of short sides of the second main surface portion 20b.

[0049] 10(a) and 10(b), when viewed in a direction in which the first main surface portion 20a and the second main surface portion 20b of the core 20 face each other, the first recess 21a and the second recess 21b each have a trapezoidal shape. Note that the shapes of the first recess 21a and the second recess 21b are not limited to trapezoidal, but are preferably trapezoidal for reasons described below. Furthermore, the shapes of the first recess 21a and the second recess 21b are the same, but may be different.

[0050] Fig. 11(a) is a schematic front view of the core 20 as viewed from the drawing direction, and Fig. 11(b) is a schematic side view of the core 20 as viewed from a direction perpendicular to the drawing direction. As will be described later, the core 20 can be formed by molding using a mold. In this case, it is preferable to provide the mold with a draft angle to make it easier to remove the molded product from the mold. For this reason, the surface of the core 20 is inclined with respect to the vertical direction.

[0051] Specifically, as shown in FIG. 11( a), when the core 20 is viewed from the drawing direction, the side surface of the core 20 is inclined with respect to the vertical direction. In this embodiment, as shown in FIG. 11( a), when the core 20 is viewed from the drawing direction, the center 20c of the side surface of the core 20 in the direction of the winding axis of the coil 10 is located at the outermost position, and the side surface of the core 20 is located more inward toward the upper and lower ends. In other words, the width of the core 20 when viewed from the drawing direction is widest at the center 20c in the direction of the winding axis of the coil 10. In this way, by configuring the side surface of the core 20 when viewed from the drawing direction so that the center 20c in the direction of the winding axis of the coil 10 is located at the outermost position, it is possible to minimize the size and improve the magnetic characteristics, as will be described later. Note that the side surface of the core 20 when viewed from the drawing direction refers to the side surface of the core 20 that covers the long sides of the coil 10.

[0052] 11(b), when the core 20 is viewed from a direction perpendicular to the drawing direction, the side surface of the core 20 is inclined with respect to the vertical direction. In this embodiment, as shown in FIG. 11(b), when viewed from a direction perpendicular to the drawing direction, the side surface of the core 20 is positioned outermost at a predetermined position 20d near the upper end and innermost at the lower end. The reason for this will be described later. Note that the side surface of the coil 10 when viewed from a direction perpendicular to the drawing direction refers to the side surface of the core 20 covering the short side of the coil 10.

[0053] Fig. 12 is a perspective view of reactor 100 that schematically shows only coil 10 and core 20 covered with insulating resin 40. As shown in Fig. 12, second recess 21b is provided in second main surface portion 20b of core 20, and therefore, when case 30 is removed, part of insulating resin 40 that covers second main surface 10b of coil 10 is exposed.

[0054] Similarly, since a first recess 21a is provided on the first main surface portion 20a of the core 20, when the case 30 is removed, a portion of the insulating resin 40 covering the first main surface 10a of the coil 10 is exposed.

[0055] 1, the case 30 has a box-like shape and includes a bottom surface 30a, a first side surface 30b, a second side surface 30c, a third side surface 30d, a fourth side surface 30e, and a lid 30f. The first side surface 30b and the third side surface 30d face each other, the second side surface 30c and the fourth side surface 30e face each other, and the bottom surface 30a and the lid 30f face each other.

[0056] The lid 30f is fixed to the first side surface portion 30b, the second side surface portion 30c, the third side surface portion 30d, and the fourth side surface portion 30e of the case 30 by screws 35 (FIG. 1). In this embodiment, the lid 30f is fixed by six screws 35, but the number of screws 35 is not limited to six, and the method of fixing the lid 30f is not limited to using the screws 35.

[0057] When viewed in a direction in which the bottom surface 30a and the lid 30f of the case 30 face each other, the first to fourth side surface portions 30b to 30e are parallel to the four sides of the coil 10 around which the conductor wire 1 is wound in a rectangular shape. Although there are irregularities on the surfaces of the first to fourth side surface portions 30b to 30e, when viewed as a flat surface ignoring the irregularities, this means that the first to fourth side surface portions 30b to 30e are parallel to the four sides of the coil 10.

[0058] The case 30 is made of a non-magnetic metal material with high thermal conductivity, such as aluminum. The thickness of the bottom surface 30a, first side surface 30b, second side surface 30c, third side surface 30d, fourth side surface 30e, and lid 30f that make up the case 30 is, for example, 2 mm.

[0059] The case 30 has a first protrusion 31a that fits into the first recess 21a of the core 20 and abuts against the first main surface 10a of the coil 10, and a second protrusion 31b that fits into the second recess 21b of the core 20 and abuts against the second main surface 10b of the coil 10 (FIG. 3). The first protrusion 31a is a portion that protrudes from the bottom surface 30a of the case 30 toward the lid 30f, and the second protrusion 31b is a portion that protrudes from the lid 30f of the case 30 toward the bottom surface 30a.

[0060] As will be described later, potting resin 60 is filled between the first protrusion 31a of the case 30 and the first main surface 10a of the coil 10, and between the second protrusion 31b of the case 30 and the second main surface 10b of the coil 10. In the present invention, the mode in which the first protrusion 31a of the case 30 and the first main surface 10a of the coil 10 abuts, and the mode in which the second protrusion 31b of the case 30 and the second main surface 10b of the coil 10 abuts also include abutment via a very thin layer of potting resin 60 or the like. Furthermore, in the reactor 100 of this embodiment, the coil 10 is covered with insulating resin 40, and therefore the mode in which the first protrusion 31a and the second protrusion 31b of the case 30 abut against the coil 10 also includes abutment with the coil 10 covered with insulating resin 40.

[0061] As described above, in reactor 100 of this embodiment, first main surface portion 20a of core 20 is provided with first recess 21a, and second main surface portion 20b is provided with second recess 21b, and case 30 has first protrusion 31a that fits into first recess 21a of core 20 and abuts against first main surface 10a of coil 10, and second protrusion 31b that fits into second recess 21b of core 20 and abuts against second main surface 10b of coil 10. With such a configuration, heat generated from coil 10 is transferred directly to case 30, thereby improving the heat dissipation performance of coil 10.

[0062] In this embodiment, the coil 10 has a structure in which the conducting wire 1 is wound flatwise and alpha wound, and the first main surface 10a and the second main surface 10b are surfaces that face each other in the direction of the winding axis. As described above, the flatwise wound coil 10 has good thermal conductivity in the direction in which the first main surface 10a and the second main surface 10b face each other, so that the abutment between the case 30 and the coil 10 in the direction of good thermal conductivity can further improve the heat dissipation of the coil 10.

[0063] Here, when viewed in a direction in which the first main surface portion 20a and the second main surface portion 20b of the core 20 face each other, if the area in which the case 30 and the coil 10 contact each other is expanded by, for example, making the first recessed portion 21a and the second recessed portion 21b of the core 20 rectangular, the heat dissipation of the coil 10 is improved but the inductance of the reactor 100 is reduced. In the reactor 100 of this embodiment, when viewed in a direction in which the first main surface portion 20a and the second main surface portion 20b of the core 20 face each other, the first recessed portion 21a and the second recessed portion 21b of the core 20 each have a trapezoidal shape, so that it is possible to both improve the heat dissipation of the coil 10 and suppress a reduction in the inductance of the reactor 100.

[0064] In the reactor 100 of this embodiment, the first recess 21a of the core 20 is provided at an end of the short side of the first main surface portion 20a, and the second recess 21b is provided at an end of the short side of the second main surface portion 20b. If the first recess 21a is provided on the long side of the first main surface portion 20a and the second recess 21b is provided on the long side of the second main surface portion 20b, the inductance of the reactor 100 will decrease significantly. However, by providing the first recess 21a on the short side, the heat dissipation of the coil 10 can be improved while suppressing the decrease in inductance.

[0065] Furthermore, in the reactor 100 of the present embodiment, a first recess 21a is provided at each of a pair of short side ends of the first main surface portion 20a of the core 20, and a second recess 21b is provided at each of a pair of short side ends of the second main surface portion 20b. This increases the area where the case 30 and the coil 10 abut, compared to a configuration in which one first recess 21a is provided at one short side end of the first main surface portion 20a and one second recess 21b is provided at one short side end of the second main surface portion 20b, thereby further improving the heat dissipation of the coil 10. Furthermore, by providing the first recesses 21a at two locations spaced apart in the longitudinal direction on the first main surface portion 20a and the second recesses 21b at two locations spaced apart in the longitudinal direction on the second main surface portion 20b, the heat dissipation of the entire coil 10 can be improved.

[0066] In the reactor 100 of this embodiment, as shown in FIGS. 2 to 4, potting resin 60 is provided in at least a portion between the coil 10 and the case 30 and in at least a portion between the core 20 and the case 30. For example, the potting resin 60 is filled to a height that is more than half to approximately 80% of the height of the case 30. The potting resin 60 is made of a non-magnetic resin, such as a silicone resin, and has a thermal conductivity of, for example, 1.6 W / mK. However, the potting resin 60 is not limited to silicone resin, and epoxy resin, urethane resin, or the like may also be used.

[0067] By providing potting resin 60 at least partially between coil 10 and case 30 and at least partially between core 20 and case 30, it is possible to reduce gaps between coil 10 and core 20 and case 30. This makes it possible to more firmly fix core 20 and coil 10 housed in case 30, and also makes it easier for heat generated from coil 10 to be transferred to case 30, thereby further improving the heat dissipation properties of coil 10.

[0068] In the reactor 100 of this embodiment, as shown in FIGS. 2 and 3 , a heat dissipation sheet 50 is disposed between the second main surface 20b of the core 20 and the lid 30f of the case 30. The heat dissipation sheet 50 is preferably disposed in contact with the second main surface 20b of the core 20 and the lid 30f of the case 30. The heat dissipation sheet 50 is made of, for example, silicone rubber and has a thermal conductivity of, for example, about 1 to 3 W / mK. The potting resin 60 described above is filled to a predetermined height inside the case 30, but is not disposed between the second main surface 20b of the core 20 and the lid 30f of the case 30. Therefore, by disposing the heat dissipation sheet 50 between the second main surface 20b of the core 20 and the lid 30f of the case 30, the gap between the second main surface 20b of the core 20 and the lid 30f of the case 30 can be reduced. This allows the heat generated by the coil 10 and transferred to the second main surface portion 20b of the core 20 to be more easily transferred to the case 30, thereby further improving the heat dissipation properties of the coil 10.

[0069] If heat can be sufficiently dissipated from the second main surface portion 20b side of the core 20, the heat dissipation sheet 50 can be omitted.

[0070] (Reactor manufacturing method) An example of a method for manufacturing the reactor 100 according to one embodiment will be described with reference to FIGS.

[0071] First, as shown in Fig. 13(a), a coil 10 is prepared. As described above, the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 are bent inward and then drawn outward. As described above, the coil 10 is preferably fixed with a fixing member 14.

[0072] Next, as shown in FIG. 13(b), the coil 10 is covered with insulating resin 40. For example, the coil 10 is covered with insulating resin 40 by transfer molding. For example, a mold is prepared, the coil 10 is placed in the mold, insulating resin is poured in and hardened, and then the mold is removed to obtain the coil 10 covered with insulating resin 40. For example, a mold having a structure divided into a lower mold and an upper mold is prepared, and the coil 10 is sandwiched between the lower mold and the upper mold.

[0073] 15 is a perspective view showing a state in which the coil 10 is placed in the first lower mold 71. The first lower mold 71 and the first upper mold that is combined with the first lower mold 71 are provided with draft angles. Note that the first upper mold has a shape that corresponds to the shape of the first lower mold 71 so that it can be combined with the first lower mold 71.

[0074] 15, when the coil 10 is placed in the first lower mold 71, the height of the end 71a of the first lower mold 71 in the longitudinal direction of the coil 10 is higher than the upper end of the coil 10. The end 71a of the first lower mold 71 in the longitudinal direction of the coil 10 refers to the end of the coil 10 opposite to the first lead portion 13a and the second lead portion 13b.

[0075] Furthermore, when the coil 10 is placed in the first lower mold 71, the height of the end 71b of the first lower mold 71 in the short direction of the coil 10 is half the height of the coil 10, i.e., approximately the same as the height of the first layer 11 of the coil 10.

[0076] FIG. 16 is an enlarged view of the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 when the coil 10 is placed in the first lower mold 71. As described above, the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 are each bent toward the inner periphery and then drawn outward. It is difficult to sandwich and fix the curved portions R1 of the first lead-out portion 13a and the second lead-out portion 13b between the first lower mold 71 and the first upper mold (not shown). Therefore, in this embodiment, the straight portions R2 of the first lead-out portion 13a and the second lead-out portion 13b are sandwiched and fixed between the first lower mold 71 and the first upper mold.

[0077] After combining the first upper mold with the first lower mold 71 in which the coil 10 is arranged, insulating resin is poured in and cured. Thereafter, the first upper mold and the first lower mold 71 are removed, thereby obtaining the coil 10 covered with the insulating resin 40.

[0078] As described above, in the coil 10 of this embodiment, the first lead portion 13a and the second lead portion 13b are positioned at the same height in the direction of the winding axis. This configuration makes it possible to simplify the structure of the mold required to form the insulating resin 40 and improve its strength. This will be explained using FIG. 17.

[0079] Fig. 17(a) is a diagram schematically illustrating how the coil 10 in this embodiment is sandwiched between a first lower mold 71 and a first upper mold 72. Fig. 17(b) is a diagram schematically illustrating how a coil 10P, in which the conductor wire is wound flatwise and alpha winding but the first lead portion 13aP is not raised to the same height as the second lead portion 13bP, is sandwiched between a first lower mold 71P and a first upper mold 72P.

[0080] In this embodiment, the first lower mold 71 for arranging the coil 10 is provided with a first groove 71H1 into which the first lead-out portion 13a of the coil 10 fits, and a second groove 71H2 into which the second lead-out portion 13b fits. These grooves 71H1 and 71H2 are provided at positions corresponding to the straight line portions R2 of the first lead-out portion 13a and the second lead-out portion 13b shown in Fig. 16. In this embodiment, the first lead-out portion 13a and the second lead-out portion 13b are located at the same height, and therefore the first groove 71H1 and the second groove 71H2 have the same depth.

[0081] 17(b) also has a first groove 71H1P into which the first lead-out portion 13aP of the coil 10P fits and a second groove 71H2P into which the second lead-out portion 13bP fits. However, as shown in FIG. 17(b), the first lead-out portion 13aP of the coil 10P is located lower than the second lead-out portion 13bP, so the depth of the first groove 71H1P is deeper than the depth of the second groove 71H2P. This makes it difficult to place the coil 10P in the first lower mold 71P having two grooves 71H1P and 71H2P of different depths.

[0082] 17(b) is provided with protrusions 73P for sandwiching the first lead portion 13aP of the coil 10P arranged in the first lower mold 71P. Because the protrusions 73P are thin, the strength of the first upper mold 72P is reduced. Furthermore, combining the first upper mold 72P having the protrusions 73P with the first lower mold 71P is more difficult than combining the first upper mold 72 without the protrusions 73P with the first lower mold 71P. Furthermore, because the protrusions 73P of the first upper mold 72P are configured to sandwich the first lead portion 13aP of the coil 10P, there is a possibility that the insulating resin will leak from the portion sandwiched by the protrusions 73P.

[0083] Next, the core 20 is formed to cover at least a portion of the coil 10 covered with the insulating resin 40 (FIG. 13(c)). For example, the core 20 is formed by compression molding. For example, a mold is prepared, the coil 10 covered with the insulating resin 40 is placed inside the mold, and resin mixed with magnetic powder is poured into the mold and hardened, thereby forming the core 20. For example, a mold having a structure divided into a lower mold and an upper mold is prepared, and the coil 10 covered with the insulating resin 40 is sandwiched between the lower mold and the upper mold.

[0084] 18 is a perspective view showing a state in which the coil 10 covered with the insulating resin 40 is placed on the second lower mold 74. The second lower mold 74 and the second upper mold that is combined with the second lower mold 74 are provided with draft angles. Note that the second upper mold has a shape that corresponds to the shape of the second lower mold 74 so that it can be combined with the second lower mold 74.

[0085] 18, when the coil 10 covered with the insulating resin 40 is placed in the second lower mold 74, the height of the end 74a of the second lower mold 74 in the longitudinal direction of the coil 10 is approximately the same as the height of the upper end of the coil 10 covered with the insulating resin 40. This is because the insulating resin 40 covering the second main surface 10b of the coil 10 needs to be exposed in order to provide the first recess 21a and the second recess 21b described above. Note that the end 74a of the second lower mold 74 in the longitudinal direction of the coil 10 refers to the end of the coil 10 opposite to the first lead portion 13a and the second lead portion 13b.

[0086] Furthermore, when the coil 10 is placed in the second lower mold 74, the height of the end 74b of the second lower mold 74 in the short direction of the coil 10 is half the height of the coil 10, i.e., approximately the same as the height of the first layer 11 of the coil 10. This is to simultaneously minimize the size of the core 20 to be manufactured and improve the magnetic properties, as will be described later.

[0087] Thereafter, the second upper mold is combined with the second lower mold 74, and then a resin mixed with magnetic powder is poured in and cured. Then, the second upper mold and the second lower mold 74 are removed, thereby forming the core 20 that covers at least a portion of the coil 10 that is covered with the insulating resin 40.

[0088] Through the above-described steps, a main part 70 of the reactor, in which the core 20 and the coil 10 are combined, is obtained (FIG. 13(c)).

[0089] As described above, in the coil 10 of this embodiment, the first lead portion 13a and the second lead portion 13b are bent inward and then led outward, which prevents the resin mixed with the magnetic powder from leaking out of the mold. This will be explained using Figures 19 and 20.

[0090] Figure 19(a) is an enlarged view of the vicinity of the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 when it is placed in the second lower mold 74. Figure 19(b) is an enlarged view of the vicinity of the first lead-out portion 13aP and the second lead-out portion 13bP of the coil 10P placed in the second lower mold 74P, in which the conductor wire is wound using flatwise winding and alpha winding, but the first lead-out portion 13aP and the second lead-out portion 13bP are not bent toward the inner periphery but are simply drawn outward. In Figures 19(a) and (b), the area into which the resin mixed with magnetic powder is poured is indicated by dots.

[0091] Fig. 20(a) is a front view schematically showing the configuration of the second lower mold 74 and second upper mold 75 sandwiching the coil 10 when viewed from the drawing direction. Fig. 20(b) is a front view schematically showing the configuration of the second lower mold 74P and second upper mold 75P sandwiching the above-mentioned coil 10P when viewed from the drawing direction. In Figs. 20(a) and 20(b), the areas where the insulating resin 40 is provided are indicated by dots.

[0092] In reactor 100 of this embodiment, first lead-out portion 13a and second lead-out portion 13b of coil 10 are formed by bending conductor 1 inward and then leading it outward, which makes it possible to prevent resin mixed with magnetic powder from leaking out of gap 91 between second lower mold 74 and insulating resin 40 covering coil 10, as shown in Fig. 19(a). This is also clear from the fact that, when second lower mold 74 is viewed from the drawing direction, only insulating resin 40 is visible around first lead-out portion 13a and second lead-out portion 13b of coil 10, as shown in Fig. 20(a).

[0093] On the other hand, when using a coil 10P in which the first lead portion 13aP and the second lead portion 13bP are not bent inward but are drawn outward, as shown in Fig. 19(b), the resin mixed with the magnetic powder may leak out from a gap 92 between the second lower mold 74P and the insulating resin 40P covering the coil 10P. That is, when the second lower mold 74P is viewed from the drawing direction, the resin mixed with the magnetic powder may leak out from a gap 92 between the second lower mold 74P and the insulating resin 40P covering the coil 10P, as shown in Fig. 20(b).

[0094] Here, it is also possible to use a second lower mold 74 in which the height of the end of the coil 10 in the short direction is approximately the same as the upper end of the coil 10 covered with insulating resin 40. However, in this case, the inductance of the manufactured reactor decreases. This will be explained using FIG. 21.

[0095] Fig. 21(a) is a front view schematically showing the shape of core 20 formed using second lower mold 74 shown in Fig. 18 when viewed from the drawing direction. Fig. 21(b) is a front view schematically showing the shape of core 20P when viewed from the drawing direction when formed using second lower mold in which the height of the end of coil 10 in the short side direction is approximately the same as the upper end of coil 10 covered with insulating resin 40. In Figs. 21(a) and 21(b), the flow of magnetic flux is indicated by arrows.

[0096] When the core 20P is formed using a second lower mold in which the height of the end of the coil 10 in the short direction is approximately the same as the top end of the coil 10 covered with the insulating resin 40, as shown in FIG. 21(b), the side of the core 20P when viewed from the drawing direction is such that the top end is located at the outermost position and the bottom end is located inward. Therefore, the thickness of the side of the core 20P when viewed from the drawing direction becomes thinner from the top end to the bottom end. Therefore, in the region D1 near the bottom end of the core 20P, the area of ​​the surface of the core 20P perpendicular to the direction of the magnetic flux is small, and therefore the inductance is low.

[0097] In contrast, in the reactor 100 of this embodiment, as shown in Fig. 21(a), when the core 20 is viewed from the drawing direction, the center 20c in the direction of the winding axis of the coil 10 is located at the outermost side. Therefore, even near the bottom end of the core 20, the area of ​​the surface of the core 20 perpendicular to the direction of the magnetic flux is not significantly smaller than that of the core 20P shown in Fig. 21(b). Therefore, the reactor 100 of this embodiment can achieve improved performance compared to a reactor using the core 20P shown in Fig. 21(b).

[0098] The following describes the manufacturing method of the reactor 100. As shown in Fig. 13(d), the main part 70 of the reactor 100 manufactured through the steps of Figs.

[0099] 14(a), a packing 80 is attached to the opening of the case 30 through which the first lead-out portion 13a and the second lead-out portion 13b of the coil 10 are drawn to the outside. The packing 80 is used to prevent the potting resin 60, which is injected using a method described below, from leaking out and to prevent moisture from entering the reactor 100 through the conductor 1, and is made of, for example, silicone resin or polycarbonate resin.

[0100] Next, as shown in FIG. 14(b), potting resin 60 is injected between the core 20 and the case 30 and between the coil 10 and the case 30. In this embodiment, injection ports 32 for injecting the potting resin 60 are provided in the first side surface portion 30b and the third side surface portion 30d of the case 30, and the potting resin 60 is injected through the injection ports 32. The injection ports 32 have shapes that protrude outward compared to other portions in the first side surface portion 30b and the third side surface portion 30d. The potting resin 60 is injected until it reaches a predetermined height within the case 30, for example, a height of approximately half to 80% of the height of the case 30. The injected potting resin 60 is then cured.

[0101] Next, as shown in FIG. 14(c), a heat dissipation sheet 50 is placed on the exposed second main surface portion 20b of the core 20.

[0102] Next, as shown in FIG. 14(d), the lid 30f is attached and fixed to the case 30 with the screws 35, without the lid 30f attached.

[0103] Through the above-described steps, the reactor 100 is obtained.

[0104] The present invention is not limited to the above-described embodiment, and various applications and modifications can be made within the scope of the present invention.

[0105] For example, in the coil 10, the conductor wire 1 is wound flatwise and alpha winding, but it may be wound flatwise and single-phase winding, or edgewise winding. In either configuration, among the lead-out portions of the conductor wire 1 of the coil 10 that are led out to the outside of the coil 10, the outermost lead-out portion of the conductor wire 1 should be configured to be bent inward before being led out to the outside.

[0106] As shown in Figure 6(a), the first and second lead-out portions 13a and 13b, which are the lead-out portions of the outermost conductor 1, are bent toward the inner periphery in a smooth curve and then led outward, but they may also be bent toward the inner periphery in a manner that connects straight lines and then led outward. [Explanation of symbols]

[0107] 1 conductor 10 coils 10a: First main surface of coil 10b Second main surface of coil 11 First layer of coil 12 Second layer of coil 13a First lead-out portion of coil 13b Second lead-out portion of coil 14 Fixing member 15 Insulating spacer 20 cores 20a: First main surface portion of core 20b Second main surface portion of core 21a First recess of core 21b Second recess of core 30 cases 31a First protrusion of case 31b Second protrusion of the case 35 screws 40 Insulating resin 50 Heat dissipation sheet 60 Potting Resin 71 First lower die 72 First upper die 74 Second lower die 75 Second upper mold 80 Gasket 100 reactor

Claims

1. A coil and a core containing a resin mixed with a magnetic material as a main component and covering at least a portion of the coil; a case that houses the coil and the core; Equipped with Among the lead-out portions, which are portions where the conductor wires of the coil are led out to the outside of the coil, the lead-out portion from which the outermost conductor wires are led out is bent toward the inner periphery and then led out to the outside, The coil has a structure in which the conducting wire is wound flatwise and alpha-wound, Each of the two drawn-out portions is bent toward the inner periphery and then drawn outward, The reactor is characterized in that the two lead-out portions are located at the same height in the direction of the winding axis of the coil.

2. The coil includes a first layer in which the conductor is wound from the outer periphery side to the inner periphery side, and a second layer in which the conductor is wound up to the innermost periphery of the first layer and then wound from the inner periphery side to the outer periphery side, The reactor according to claim 1 , further comprising an insulating spacer disposed between the first layer and the second layer.

3. A coil and a core containing a resin mixed with a magnetic material as a main component and covering at least a portion of the coil; a case that houses the coil and the core; an insulating resin that covers at least a portion of the coil; Equipped with Among the lead-out portions, which are portions where the conductor wires of the coil are led out to the outside of the coil, the lead-out portion from which the outermost conductor wires are led out is bent toward the inner periphery and then led out to the outside, When the coil covered with the insulating resin is viewed from a direction in which the conductor wire is drawn out, a surface of the insulating resin covering a side surface of the coil is inclined with respect to a vertical direction, A reactor characterized in that the thickness of the insulating resin covering the side surface of the coil when viewed from the drawing direction is thickest at the center in the direction of the winding axis of the coil.

4. The reactor according to claim 3 , wherein the insulating resin is provided so as to cover at least a curved portion of the lead-out portion of the conductor.

5. A coil and a core containing a resin mixed with a magnetic material as a main component and covering at least a portion of the coil; a case that houses the coil and the core; Equipped with Among the lead-out portions, which are portions where the conductor wires of the coil are led out to the outside of the coil, the lead-out portion from which the outermost conductor wires are led out is bent toward the inner periphery and then led out to the outside, When the core is viewed from a direction in which the conductor wire is drawn out, a side surface of the core is inclined with respect to a vertical direction, A reactor characterized in that the side surface of the core has a center located at the outermost side in the direction of the winding axis of the coil.

6. The reactor according to any one of claims 1 to 5, wherein the coil is fixed by a fixing member.

7. the core includes a first main surface portion covering a first main surface of the coil and a second main surface portion covering a second main surface of the coil opposite to the first main surface, the first main surface portion having a first recess and the second main surface portion having a second recess; The reactor according to any one of claims 1 to 6, characterized in that the case has a first convex portion that fits into the first recess of the core and abuts against the first main surface of the coil, and a second convex portion that fits into the second recess of the core and abuts against the second main surface of the coil.

Images